Profiled Wear Plate with Additive Outer Layer

Solution Overview

Problem

Wear plates and pressure plates in baling presses experience rapid wear due to mechanical stress, requiring frequent replacement and costly, time-consuming machining of hard metal sheets, especially when profiling is involved.

Innovation Solution

A multilayer structure comprising a carrier made of a less expensive metal or metal alloy with an outer layer of higher hardness applied via additive manufacturing, such as 3D printing, to create a profiled surface that reduces material costs and machining time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hard metal sheets (HBW 400-500) are used to produce wear plates with extended service life, then durability is improved, but machining time and cost increase significantly

Engineering Contradiction:

Improveservice life of wear plateVSAvoidmachining time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The wear plate is segmented into two functional zones: a carrier made of softer, easier-to-machine metal and an outer layer made of hard wear-resistant metal. This segmentation allows each zone to be optimized independently - the carrier for ease of manufacturing and the outer layer for durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wear plate uses a composite structure combining two different metals: a carrier metal (softer, easier to machine) and an outer layer metal (harder, more wear-resistant). This composite approach allows the plate to exhibit both ease of manufacture and extended service life by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If hard metal sheets are used to produce wear plates, then durability is improved, but machining cost increases due to expensive tools

Engineering Contradiction:

Improveservice life of wear plateVSAvoidmachining cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The wear plate is segmented into two functional zones: a carrier made of softer, easier-to-machine metal and an outer layer made of hard wear-resistant metal. This segmentation allows each zone to be optimized independently - the carrier for ease of manufacturing and the outer layer for durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wear plate uses a composite structure combining two different metals: a carrier metal (softer, easier to machine) and an outer layer metal (harder, more wear-resistant). This composite approach allows the plate to exhibit both ease of manufacture and extended service life by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

3Reliability

If profiled surfaces are machined on hard wear plates, then functional engagement is improved, but machining time and complexity increase

Engineering Contradiction:

Improveengagement capabilityVSAvoidmachining complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wear plate is segmented into two functional zones: a carrier made of softer, easier-to-machine metal and an outer layer made of hard wear-resistant metal. This segmentation allows each zone to be optimized independently - the carrier for ease of manufacturing and the outer layer for durability.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution extends the service life of wear plates and pressure plates by providing a durable, evenly thick outer layer that mitigates mechanical stress, reducing material expenses and production time while maintaining effective profiling.

Implementation Method 1

a material applied to the carrier by an additive manufacturing process and firmly connected to it an outer layer of a second metal or metal alloy

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

The generative method can be selective laser melting, selective electron beam melting or selective laser sintering

Methodology Applied

Scientific EffectSelective laser melting: Laser Beam Welding

Implementation Method 3

The generative method can be selective laser melting, selective electron beam melting or selective laser sintering

Methodology Applied

Scientific EffectSelective electron beam melting: Electron Beam

Implementation Method 4

The generative method can be selective laser melting, selective electron beam melting or selective laser sintering

Methodology Applied

Scientific EffectSelective laser sintering: Laser Beam Welding

Data Source

PatentEP3053678B1Metal wear sheet or pressure plate for packing presses containing contoured surface, manufacturing method thereof and packing press

Publication Date: 2018.08.01 BERKENHOFF GMBH

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AI summary

The present invention relates to a metal part with a profiled surface, in particular a wear plate for scrap presses, wherein the metal part comprises a carrier (1) made of a first metal and an outer layer (2) made of a second metal or a hard metal, applied to the carrier (1) by an additive manufacturing process and firmly bonded to it, wherein the outer layer (2) has a higher hardness than the carrier (1) and the profiled surface of the metal part is formed by an outer surface of the outer layer (2).